Process Design Parameters

• Design:
• “To design” refers to the process of originating
and developing a plan for a product, service or
process.

• Process:
• Is any part of an organization which takes a set
of input resources which are then used to
transform something into outputs of products or
services.
 Process Design

Process design

Processes that Processes that

Design Products Produce Products
and Services and Services
Supply Network Design
Concept Generation

Screening
Layout
and Flow
Preliminary Design

Evaluation and
Improvement
Process Job
Technology Design
Prototyping and final
design
Process mapping
• Used to identify different types of activities.
• Shows the flow of material, people or
information.
• Critical analysis of process maps can improve
the process.
Process mapping symbols
Operation (an activity Beginning or end of process
that directly adds value)

Inspection (a check of Activity

some sort)
Transport (a movement Input or Output from the process
of some thing)

Delay (a wait, e.g. for materials) Direction of flow

Storage (deliberate storage, Decision (exercising discretion)

as opposed to a delay)

Process mapping symbols derived Process mapping symbols derived

from “Scientific Management” from Systems Analysis
 Raw Stored Move to Stored Take
Assembly Sell
Materials Sandwiches Outlets Sandwiches Payment

Standard sandwich process

Customer
Request
Raw Assembly Take
Materials Payment

Customer
Request

Customized sandwich old process

 The operation of making and
selling customized sandwiches
Assemble as Take
Prepare required payment
Sandwich Customers
materials and “assembled” to
customers sandwiches

Bread and
Base filling The outline process of making and
selling customized sandwiches
Assemble whole
sandwich
Use standard
“base”?
No

Yes Fillings
Customer The detailed process of
Request assembling customized
Assemble from
sandwiches
standard “base”
Stored
“Bases”
 Customized sandwich improved new process

Assemble whole
sandwich

Assembly of Use standard Take

“sandwich No
“base”? Payment
bases”

Fillings

Bread and Yes

Base filling Customer Request

Stored “Bases” Assemble from

standard “base”
 Conventions and Format Recommended for Laying Out a Block Flow
Process Diagram

• 1. Operations shown by blocks.

• 2. Major flow lines shown with arrows giving direction
of flow.
• 3. Flow goes from left to right whenever possible.
• 4. Light stream (gases) toward top with heavy stream
(liquids and solids) toward
• bottom.
• 5. Critical information unique to process supplied.
• 6. If lines cross, then the horizontal line is continuous
and the vertical line is broken
• 7. Simplified material balance provided.
 PROCESS FLOW DIAGRAM (PFD)
• A typical commercial PFD will contain the following information:
• 1. All the major pieces of equipment in the process will be represented on the
diagram
• along with a description of the equipment. Each piece of equipment will have
• assigned a unique equipment number and a descriptive name.
• 2. All process flow streams will be shown and identified by a number. A
description of
• the process conditions and chemical composition of each stream will be included.
• These data will be either displayed directly on the PFD or included in an
accompanying
• flow summary table.
• 3. All utility streams supplied to major equipment that provides a process
function
• will be shown.
• 4. Basic control loops, illustrating the control strategy used to operate the process
during
• normal operations, will be shown.
Symbols for Drawing Process Flow
Diagrams
Skeleton Process Flow Diagram (PFD)
for the Production of Benzene via the
Hydrodealkylation of Toluene
material flow balance
• Material balance is also useful tool for the
following:
• 1. The study of the plant operation &
troubleshooting.
• 2. Check performance against design.
• 3. Check the instrument calibration.